Apparatus and method for binding a load with tape

ABSTRACT

An apparatus for binding a three-dimensional load with tape comprises a turntable for rotating the load, a tape dispenser and a logistical controller. The tape dispenser is moveable relative to the turntable and the load. The detector detects the top of the load, and is moveable with the tape dispenser. The logistical controller is arranged to control rotation of the load and movement of the tape dispenser. In particular, the controller is arranged to operate the apparatus to dispense the tape according to a predetermined default pattern until the detector determines the top of the load. Once the tope of load is detected, the controller is arranged to operate the apparatus according to a corrected pattern based upon the detected top of load. Further, the controller may comprise a computer program which calculates the required turntable speed for a substantially constant predetermined speed of the carriage such that the relative position of the turntable and the carriage is such that the load is bound according to the default pattern or the corrected pattern.

RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. Ser. No.10/398675 entitled “Method and apparatus for wrapping a load”.

FIELD OF THE INVENTION

The present invention relates to an apparatus and method for binding aload with tape. In particular, although not exclusively, the inventionrelates to a tape binding apparatus of the type in which a palletisedload to be secured is rotated on a turntable and the tape is dispensedfrom a tape dispenser which moves up and down on an upright mastalongside the rotating load to dispense the tape in particular patternsover the load.

BACKGROUND OF THE INVENTION

Conventionally, stretch film is used to wrap a palletised load. The loadis supported on a turntable and the stretch film is dispensed from aroll of film which resides on a moveable carriage which moves up anddown alongside the palletised load. The carriage advances so that thefilm is dispensed in a spiral. The pitch of the spiral is such that theedges of the film overlap the previous layer. The carriage includes aphotoeye so that as it advances upwards, the photoeye detects the top ofthe load so that after a brief delay, the carriage will then commence tomove downwards. Since the pitch is chosen to enable the film to overlap,the sides of the load will be completely enshrouded in the stretch filmat the completion of one upward and downward pass of the stretch film.

Stretch film has inherent drawbacks in that there is considerablewastage of material since at the destination of the load, the film issimply cut from the load and is not reused. Another drawback in the useof stretch film is that some products once palletised need to breathe toallow cooling and avoid condensation or sweating. This can lead todouble handling of the loaded pallets or loss of product from a palletbefore wrapping.

Tape dispensers have become known which apply an adhesive tape which isstretchable to maintain tension in the tape. The adhesiveness tends todiminish as the tape is stretched. The tape can be applied to the loadby rotating the load on a turntable and dispensing the tape from amoveable carriage which moves up and down alongside the load. Unlikestretch film, the carriage moves up and down more than once, usuallyabout four times up and down to produce a pattern of crisscrossingupward and downward helixes. However, unlike stretch film wrapping whichenshrouds the load, the tape must be applied with precision so that theresulting tape pattern will effectively secure the load. The tapepattern may be dependent upon the dimensions of the particular items inthe load as is described in our earlier application (Ser. No.10/398675), from which the present application is acontinuation-in-part. The contents of the earlier application Ser. No.10/398675 are incorporated herein by reference.

Therefore, in order to effectively bind a load with tape, a precisepattern must be adhered to and accordingly, the overall dimensions ofthe load are known in advance to produce the precise pattern. Thus, withexisting tape binding apparatus, the operator is required to key in theheight of the load and for this he will likely need to use a tapemeasure. Additionally, the operator will be required to enter an “X”value which equates to the number of sides the load is rotated throughfor the inclined tape paths to traverse from the bottom to the top.Also, in the completed pattern, the “X” number will equate to the numberof crosses formed in tape on each side of the load. This entry of data,especially the measuring step is time consuming.

Another issue for existing tape binding apparatus is that it isrelatively slow in comparison to conventional stretch film wrappingapparatus. One of the reasons for this is that the tape dispensingcarriage needs to traverse up and down at least four times in order tocreate the desired binding pattern. In contrast, stretch film wrappersonly need to traverse up and down once. Furthermore, in binding apalletised load which is generally rectangular or square incross-section, the carriage will generally pause to wait for theturntable to rotate to present each side of the load to which tape is tobe applied. This also slows down the tape binding process. There arelimits to which the carriage can be moved, firstly, for reasons ofoperator safety. Secondly, the carriage needs to change direction anumber of times and there is therefore a maximum speed that the carriagecan travel in order to decelerate within a reasonable time and distance.

Another particular problem encountered by tape binding apparatus whichis not so problematic with film wrappers is that of partial top layerson a pallet. With stretch film wrapping, partial layers are easily dealtwith since the stretch film can still cocoon around the partial layer.However, a partial layer is not so easily handled with a relatively thinpiece of tape.

It is therefore an object of the present invention to overcome at leastsome of the aforementioned problems.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the present invention there isprovided an apparatus for binding a three-dimensional load with tape,the apparatus comprising:

a turntable for supporting and rotating the three-dimensional load;

a tape dispenser for dispensing tape, the dispenser being moveablerelative to the turntable and the load;

a logistical controller arranged to control rotation of the load andmovement of the tape dispenser; and

a detector to detect the top of the load, the detector being moveablewith the tape dispenser, wherein the controller is arranged to operatethe apparatus to dispense the tape according to a predetermined defaultpattern until the detector determines the top of the load, whereafter,the controller is responsive to a signal from the detector correspondingto the detected top of load to operate the apparatus according to acorrected pattern based upon the detected top of load.

The detector may be in the form of an electronic light detector whichdetects reflected light. The detector may include a light source and maydetect reflected light from the load. Alternatively, the detector maydetect reflected light from a spaced sensor. The light source may beinfra-red or laser. The detector is not limited to an electronic lightdetector and may be any other kind of known limit detector.

The detector is moveable with the tape dispenser. Accordingly, if thetape dispenser is provided on a moveable carriage driven up and down amast, then the detector may be mounted on the carriage. Preferably, thedetector is spaced above the taped dispenser and as such, providesadvance warning to the controller that the tape is approaching the topof the load.

A typical pattern which may be applied to the load is a helical patternwhere the tape dispenser moves up and down relative to the load as theturntable is driven to rotate. Accordingly, the tape travels in anupward continuous helix and then a downward continuous helix.Additionally, substantially level passes of the tape may be applied tothe load subsequent to each upward traverse and also subsequent to eachdownward traverse.

In the abovementioned exemplary pattern, the controller operates theapparatus to dispense the tape in the predetermined default pattern byselecting a default pitch. The dimension of pitch is the verticaldistance between the ends of the tape on one side of the load. In apreferred form of the invention, the controller operates the apparatusto initially dispense tape to create an upward helix on the load. Thetape is applied at a default pitch until the detector determines thatthe top of the load has been reached. Once the controller is aware ofthe dimensions of the load, the controller then operates the apparatusaccording to a corrected pattern. In the exemplary helical patterndescribed above, the tape will be applied to a portion of the loadbetween a user defined upper or lower limit. To apply the correctedpattern, a corrected pitch is calculated so that the tape will beapplied to a whole number of side of the load as it traverses betweenthe upper and lower limit and vice versa.

While it has been described above that the exemplary helical pattern maycommence with an upward helix, this need not be the case. The patternmay commence intermediate the height of the load and first helix downbefore winding back up. This particular variation may enable the tape tocommence at a convenient height for the user to save the user having tobend down to apply the tape to the load.

The pattern applied to the load is not limited to the exemplary helicalpattern described above and other patterns may be applied to the load.For example the helixes need not be continuous and one or morehorizontal bands may be applied during the upward or downward traverseof the tape. Furthermore, looping over the top of the load between theupward and downward traverse is also included within the scope of theinvention.

The controller may receive a number of user inputs through the use of akeypad or other data entry means. The tape need not be applied to thewhole of the load and in fact the top limit of the tape is generallyspaced below the top of the load. In the looping example, there may be atop limit of the helical pattern with still looping over the top of theload. Furthermore, the tape may be applied to the pallet which supportsthe load. Accordingly, the pattern between these upper and lower limitsmay be referred to as the pattern array. The user may input into thecontroller the upper limit of the pattern array and the lower limit ofthe pattern array. The user may input the upper limit by entering avalue of top drop which is defined as the distance from the top of theload. This avoids the need to measure the overall load height.

The user may also input the pallet dimensions. It is also possible forthe user to enter a variation into the calculated pattern. For examplein the above described helical pattern there is a whole number ofcrosses applied to each side of the load and the default number ofcrosses (X value) is determined by the controller. Accordingly, the usercan input a variation to increase or decrease the number of crosses oneach side of the load, by way of a whole number. The user may also inputa maximum turntable speed.

The turntable may be driven by a motor and the carriage may be driven byanother motor. The controller controls operation of both the turntablemotor and the carriage motor. Feedback may be provided to the controlleras to the turntable orientation. Feedback may also be provided as to theheight of the carriage. For example, feedback may be provided by adetector determining the passing of teeth of a toothed wheel.

The controller is able to calculate the array height by determining thecarriage height when the top of the load is detected. There may be anadjustment for the offset between the carriage height and the actuallocation of the detector. From this, the lower limit dimension and thetop drop are deducted to obtain the array height. The corrected patternis then based on the array height.

By way of example, in the helical pattern, the number of crosses iscalculated by dividing the array height by the default pitch androunding this to the nearest whole number to arrive at a value for thenumber of crosses (X value). The corrected pitch is then calculated bydividing the array height by the X value.

As previously mentioned, the detector will provide advance warning thatthe tape is approaching the top of the load. Accordingly, the controllermay determine an adjustment which is required so that the tape reachesthe upper limit coinciding with the end of an inclined pass across aside of the load.

In accordance with the second aspect of the present invention there isprovided a method of binding a three-dimensional load with tape, themethod comprising:

-   a) binding the load with tape dispensed from a movable tape    dispenser according to a default pattern;-   b) detecting the top of the load by a detector moveable with the    tape dispenser during step a); and-   c) binding the load with a corrected pattern based on the detected    top of load.

The above method is preferably carried out in a tape binding apparatus,the operation of which is controlled by a controller. The tape bindingapparatus may include a turntable to rotate the load and a verticallymoveable carriage on which the tape dispenser is provided. Thecontroller may control the turntable and the carriage speed toeffectively wrap the load. The controller may access stored defaultpattern parameters for operating the apparatus according to the defaultpattern. The controller may also receive a signal from the detectorcorresponding to the top of load. The controller then uses this receivedinformation to calculate the height of the array i.e. the portion of theload intended to be bound and then operates the apparatus according to acorrected pattern. Any of the features described above in connectionwith the first aspect may be applied to the second aspect of theinvention.

In accordance with a third aspect of the present invention there isprovided an apparatus for binding a load with tape, the apparatuscomprising:

-   a turntable to rotate the load;-   a carriage to carry a tape dispenser for movement along an upward    path and a downward path adjacent the load;-   a controller to control the movement of the turntable and the    carriage to bind the load according to a desired pattern, wherein    the controller comprises a computer program which calculates the    required turntable speed for a substantially constant predetermined    speed of the carriage over a substantial portion of the upward path    or a substantial portion of the downward path such that the relative    position of the turntable and the carriage is such that the load is    bound according to the desired pattern.

The desired pattern may be one which is predetermined i.e. it may be adefault pattern. Alternatively, the desired pattern may be one which iscalculated during the binding sequence i.e. once the top of the load isdetected, as with the first aspect of the invention.

It will be appreciated that in the upward path of the carriage, whilethe turntable rotates, the tape will be applied in an upward helix tothe load. Similarly in the downward path of the carriage, while theturntable continues to rotate in the same direction, the tape will beapplied in a downward helix onto the load. The carriage speed may beconstant over a substantial portion of both of these paths. Preferably,the speed of the carriage is constant over an intermediate portion ofthe paths which allows for acceleration and deceleration at the extremesof the paths. Furthermore, the carriage may have two possible constantspeeds being a fast speed and a slow speed. The slow speed may be usedto apply the default pattern as described in connection with the firstaspect of the invention. The fast speed may be used to apply thecorrected pattern.

The turntable may be driven by a variable speed drive which may beinfinitely variable up to a maximum speed which will either bedetermined by the parameters of the drive or may be determined by a userinput into the controller. The controller may provide an analog outputto the variable speed drive.

A digital output may be provided from the controller to the carriagedrive. The digital signals may be one of up, down or fast.

In a preferred embodiment of the invention, the load intended to bebound will be square or rectangular. The controller may be adapted toreceive user inputs of the dimensions i.e. length and width.Accordingly, the desired pattern for the tape may be broken down intoquarter turn segments. In this manner the computer program maycalculate, for the next quarter turn of the turntable, where thecarriage is required to apply tape according to the desired pattern andwhen the carriage will arrive at a particular position given theconstant speed and then calculates the speed of the turntable requiredto rotate the load through the quarter turn.

The desired pattern may not be limited to a helix up and helix down andadditionally may incorporate other features including looping, bandingand an initial home position as described above in accordance with thefirst aspect of the present invention. In particular, the step oflooping takes place between the upward path and the downward path by thetape crossing over the top of the load at the corner instead oftraversing the corner at the sides of the load. This providesadditionally securement at the top of the load. Additionally, where theload is provided with a sheet of flexible plastic or board at the top ofthe load, the looping can be used to secure this sheet.

The feature of looping may be an operator selected option which theoperator may select through a key pad, this option being conveyed to thecontroller. Once the looping option is selected, it is applied betweeneach upward path and downward path in the binding sequence.

The operator may also adjust the parameters of the looping. For example,the operator may be able to adjust the overshoot. This is the distanceabove the top of the load to which the carriage travels to apply thetape in a loop over the corner. A high overshoot will create a loopwhich is more greatly spaced from the corner than a loop resulting froma low overshoot.

In looping, the carriage still travels at a constant predetermined speedand the computer calculates the required turntable speed for theturntable to be in the correct position at the conclusion of thecarriage overshoot. In practice, this may result in the turntable speedbeing quite slow.

In accordance with the fourth aspect of the present invention there isprovided an apparatus for binding a load with tape, the apparatuscomprising:

-   a turntable for supporting and rotating the three-dimensional load;-   a tape dispenser for dispensing tape, the dispenser being moveable    relative to the turntable and the load; and-   a logistical controller arranged to control rotation of the load and    movement of the tape dispenser; wherein the controller is arranged    to operate the apparatus to dispense the tape according to a desired    pattern comprising a plurality of helical paths, each path including    at least one upward helix, a loop over the top of the load and a    downward helix giving rise to a pattern whereby the upward and    downward helixes are transversely spaced from each other and each    upward helix crosses with at least one downward helix.

The controller may be operated in such a way that the looping isconducted in the manner described above in connection with the thirdaspect of the invention.

The operator may be able to input an overshoot parameter into thecontroller to affect the looping characteristics. An invention may alsoreside in a method of binding a load with tape so as to effect loopingover the top of the load.

In accordance with the fifth aspect of the present invention there isprovided an apparatus for binding a three-dimensional load with tape,the apparatus comprising a turntable for supporting and rotating thethree-dimensional load; a tape dispenser for dispensing tape, thedispenser being moveable relative to the turntable and the load; and alogistical controller arranged to control rotation of the load andmovement of the tape dispenser, wherein the logistical controllercontrols the operation of the apparatus to bind the load with tapeaccording to a desired pattern; and means for inputting into thelogistical controller, one or more values corresponding to one or moreselected heights, wherein the logistical controller controls theoperation of the apparatus to apply substantially horizontal over-bandsover the desired pattern at the one or more selected heights.

The invention may incorporate any of the features described above inaccordance with the above aspects of the invention. In particular, thedesired pattern may be the helical pattern described above which isapplied to the substantially the full extent of the load and mayoptionally include looping. The benefit of the over-banding is that theunderlying tape of the helical pattern may be cut down to the uppermostover-band and that portion of the tape removed. The over-banding retainsthe remainder of the tape binding in place so that a portion of the loadmay be removed. This makes it possible to load onto a single pallet,boxes or items which are intended for different destinations. If thereare three destinations then two over-bands may be applied. Theunderlying tape of the helical pattern is removed down to the firstover-band at the first location. At the second location, the firstover-band is removed and the tape of the helical pattern is cut to alevel above the second over-band. At the third location, all of the tapemay be cut to deliver the remainder of the load.

An invention may also reside in a method of binding a load in a mannerwhich produces overbands.

In accordance with a sixth aspect of the present invention there isprovided an apparatus for binding a three-dimensional load with tape,the apparatus comprising:

-   a turntable for supporting and rotating the three-dimensional load;-   a tape dispenser for dispensing tape, the dispenser being moveable    relative to the turntable and the load; and-   a logistical controller arranged to control rotation of the load and    movement of the tape dispenser to dispense tape onto the load in a    desired pattern, wherein the controller is programmed to position    the tape dispenser at a home position which is at a convenient    height for the user to position tape on the load and wherein the    controller is arranged to control movement of the tape dispenser to    a start position to commence application of tape to the load in the    desired pattern.

The above aspect of the invention may incorporate any of the featuresdescribed in the above aspects.

BRIEF DESCRIPTION OF THE DRAWINGS

To facilitate an understanding of the invention, reference is made inthe description to the accompanying drawings where the invention isillustrated in several preferred embodiments. It is to be understood,however, that the invention is not limited to the preferred embodimentsillustrated in these embodiments.

In the drawings:

FIG. 1 is a plan view of a tape binding apparatus according to a firstembodiment of the invention;

FIG. 2 is a side view of the tape binding apparatus shown in FIG. 1;

FIG. 3 is a detailed sectional plan view showing various components ofthe turntable and a drive means for driving the turntable of the tapebinding apparatus of FIG. 1;

FIG. 4 is a side sectional view of the turntable shown in FIG. 3;

FIG. 5 is a side view of a mast assembly together with a carriageassembly and tape dispenser of the tape binding apparatus shown in FIG.1;

FIG. 6 is an end view of the tape binding apparatus shown in FIG. 5;

FIG. 7 is a plan view of the tape binding apparatus shown in FIG. 5;

FIGS. 8 to 10 are enlarged views of FIGS. 5 to 7 respectively;

FIG. 11 is a schematic diagram illustrating various functionalcomponents of a control system for controlling the operation of the tapebinding apparatus shown in FIGS. 1 to 10;

FIG. 12 is a side view of the mast assembly and a load supported on theturntable showing attachment of the tape to the load;

FIGS. 13 and 14 are a flow chart illustrating steps performed by thecontrol system shown in FIG. 11 to control operation of the tape bindingsystem shown in FIGS. 1 to 10;

FIGS. 15 to 20 show exemplary loads when bound with various tape bindingpatterns by the tape binding system shown in FIGS. 1 to 10;

FIGS. 21 and 22 provide various views of each of the sides of a load asit is bound by tape from the tape binding apparatus shown in FIGS. 1 to10;

FIG. 23 is a schematic view of a modified form of a tape bindingapparatus;

FIGS. 24 and 25 provide various diagrammatic views of each of the sidesof a load as it is bound with tape with the tape binding apparatus ofFIG. 23;

FIGS. 26 a and 26 b are diagrammatic views of two adjacent sides of theload illustrating placement of the tape in looping over the top of theload;

FIG. 26 c is a plan view of the load of FIGS. 26 a and 26 b;

FIGS. 27 a and 27 b are diagrammatic views of two adjacent sides of aload with a variation in the looping over the top of the loads;

FIG. 27 c is a plan view of the load of FIGS. 27 a and 27 b;

FIGS. 28 and 29 are various diagrammatic views of each of the sides of aload as it is bound by tape using the step of looping;

FIG. 30 is a perspective view of a load which is bound with tape withthe additional feature of overbanding.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Referring to FIGS. 1 to 4, there is shown generally an apparatus 2 forpalletising and binding a load 18. The apparatus 2 comprises a turntable4, a mast 8 extending vertically from and connected to a base plate 10,a carriage assembly 12 supported on the mast 8 for verticalreciprocating motion with respect to mast. Carriage assembly 12 includesan arm assembly 14 and a roll mounting assembly 16 which supports a rollof tape 80 to be dispensed therefrom and wound around the load 18located on the turntable 4. The arm assembly 14, roll mounting assembly16 and roll 17 form part of a tape dispensing arrangement 13 forapplying tape to the load 18. Both the arm assembly 14 and the rollmounting assembly 16 may be integrally formed with the carriage assembly12 or connected directed to the carriage assembly 12. A pre-tensioningassembly 20 is connected to the carriage assembly 12, and acts topre-tension the tape dispensed from the tape dispensing means 13. Thetape is preferably #8884 or #8886 manufactured by Minnesota Mining &Manufacturing (3 M) Company, or tape as disclosed in the specificationof U.S. Pat. No. 5,496,599 in the name of 3 M. Details a pre-tensioningassembly 20 are disclosed in our earlier application Ser. No. 10/398675.

The turntable 4 is adapted for rotational movement about a central hub24. The turntable 4 includes a top plate and a bottom plate. Locatedbetween the top and bottom plates is a belt 28 which drives a pulley 26.The belt 28 is driven by a drive wheel/pulley 30 driven by an electricmotor 32, or other turntable drive means. In an alternative embodiment,the pulley may comprise a circular sprocket 26 which has teeth adaptedto engage an endless drive chain 28 which passes around a sprocket 26.

Referring to FIGS. 5 to 10, the vertical reciprocating motion of thecarriage assembly 12 is enabled by a sprocket and pulley arrangementmounted at opposing ends of the mast 8. A drive chain 42 is attached topart of the carriage assembly 12. An electric motor 44 or other carriageassembly drive means causes the rotational movement of a drive sprocket46 located at a lower end of the mast 8 by means of drive shaft 48. Apulley 50 is mounted to the upper end of the mast 8. Alternately, thepulley 50 may be replaced by a sprocket which includes teeth to engagethe chain 42.

The carriage assembly 12 includes a carriage tube 52 adapted to fitaround the periphery of the mast 8 to enable slidable movementtherealong. The movement of the carriage assembly 12 along the mast 80is enabled by connection of the drive chain 42 to the carriage tube 52by way of suitable connection such as depending lugs or flanges 54 and56 located on the outer surface of the carriage tube 52.

The movement of the carriage assembly 12 vertically up and down the mast8, in conjunction with the rotation of the turntable 4, enables the tape80 to be wound around the palletised load 18 in a helical or circularmanner. Particular patterns of the helical/circular binding are able tobe applied to the load 18 by controlling the rotational movement of theturntable 4 and the movement and position of the carriage assembly onthe mast 8.

A control panel structure 67, shown in FIG. 2, is connected to the mastassembly 8 for attachment of an electronic circuit board and a display68. Electric cables run to and from the circuit board 68 and fromsensors 60, located near the toothed wheel 62, and 64 located near thetoothed wheel 66. The toothed wheel 60 is mounted to the turntable 4about the central hub 24, whilst the toothed wheel 66 is mounted aboutthe shaft of the motor 44. The sensor 60 is mounted adjacent the toothedwheel 62 to sense the number of teeth of the toothed wheel passing infront of the sensor to thereby provide an indication of the angularposition or rotation of the turntable 4. The sensor 64 is mountedadjacent the toothed wheel 66 in order to sense the number of teethpassing on the toothed wheel 66 before the sensor 64 in order toindicate the displacement of the carriage assembly 12 along the mast 8.

The sensors 60 and 64, and corresponding toothed wheels 62 and 66 formpart of a control system 100 for controlling the rotation of theturntable 4 and the movement of the carriage assembly up and down themast 8, to thereby control the binding process of the palletised load18.

As can be seen in FIG. 11, the sensors 60 and 64 form part of a controlsystem 100 for controlling operation of the motors 32 and 44. Power issupplied from the mains supply 102 to a Variable Frequency Drive (VFD)106 adapted to drive the motor 44 controlling carriage assemblymovement, and VFD 106 driving the motor 32 controlling turntablerotation. Power is also supplied to carriage drive 104. The VFD 104 and106 are supplied with 240 volts AC from the mains supply 102.

A controller 108 is supplied with 12 volts DC from the mains supply 102through a transformer 110. The controller 108 is housed in the controlpanel structure 67 attached to the mast assembly 8. Control signals aresent from the controller 108 to the control signal input terminals ofthe VFDs 104 and 106 in accordance with instructions fetched from thePROM 112 storing a computer program. The control signals supplied by thecontroller 108 are dependent upon the output signals of the sensors 60and 64, which are supplied to the controller 108. A keypad 114 isprovided to enable the entry of data by the operator, whilst a display116 and other associated indicators display selected information to theoperator.

Typically, the keypad 114 and display 116 are accessible through thepanel 68 shown in FIG. 2.

Each of the sensors 60 and 64 is adapted to transmit a pulse every timea tooth, respectively of toothed wheels 62 and 66, passes in front ofthe sensor. The number of pulses that must be received by the controller108 from the sensor 60 to correspond to a 90° rotation of the turntable4 is pre-stored in the controller 108 so that when an internal counterreaches that number of pulses, the controller is able to detect aquarter turn rotation of the turntable 4. Similarly, the movement of thecarriage assembly 12 up and down the mast 8 and the number of pulsesemitted by the sensor 64 are calibrated that by counting the number ofpulses received from the sensor 64 the controller 108 is able todetermine the distance travelled along the mast.

In FIG. 12 there is shown a side view of the load 18 supported by apallet 23. The pallet and load are mounted on the turntable 4. In thisexample, the load 8 includes 4 layers 19, each consisting of a series ofsixteen containers 21.

The length of the load 18 is a fixed distance L_(p), whilst the distancefrom the rear of the load 18 to the point on the tape dispensing means20 from which the tape is dispensed is also a fixed distance L_(c). Inthis example, a pattern of tape is intended to be applied to the load18, with the tape 80 running between points 25 half way along the heightof each box 21. In the position shown in FIG. 12, it is desired for thetape 80 to run from a point halfway up the corner of the left mostcontainer of the lower layer of the load 18 to a point halfway up thecorner of the container the second lowermost layer. The verticaldistance between points 25 is referred to as “pitch”.

The controller 108 may be programmed with data corresponding to thevarious distances L_(p) and L_(c) and the pitch H_(b). However, it ispreferred that the operator will enter certain dimensions which includethe pallet dimensions of length L_(p) and breadth (not shown) and heightH_(l). However, it is more common practice that the operator enters avalue of “top drop”. Top drop T_(d) is the distance from the top of theload down to the point which the operator wants to be the uppermostlimit of the tape. In this example, that would correspond to thedistance from the top of load 18 down to the point 25 in the uppermostlayer. Generally, the dimension of top drop corresponds to half theheight of the top layer. The operator may also enter the minimum tapeheight which is the height from the bottom of the load to the lowest runof tape H_(min) (see FIG. 15) although a default value may be provided.The operator may also enter the height of the load and an X value whichequates with the number of crosses made on each side of the load oralternatively equates with the number of sides of the load to bepresented for the tape to traverse from H_(min) to reach the upper limitdefined by top drop.

Thus, the controller 108 can calculate from the entered values of loadheight, top drop and minimum tape height, a value of array height A (seeFIG. 15) which is the height of the portion of the load to be bound withtape. By dividing this value by the X value, the controller candetermine the pitch H_(b). Generally speaking, the distance L_(c) willbe already programmed and not necessary to be entered by the operator.Instead of entering the X value, the operator may simply enter thenumber of layers in the load. Alternatively, the operator need not enteran X value or the number of layers, instead, the controller couldcalculate a pitch from the array height and the dimension of top drop.

Alternatively, the operator could enter the height of each layer and thenumber of layers. From this, a load height can be determined (assuming adefault pallet size). A default top drop based on half the height ofeach layer could thus be used to determine array height. Thusdetermination of pitch could be made on the information about the heightof each layer, given the desirability of crossing points 25 midway alongthe height of each layer.

Thus, the characteristics of the load may be entered into the controllerthrough the keypad using various different aspects of the load includingheight of the load, top drop, height of each layer, number of layers,pallet dimensions of length and breadth, desired number of crosses (Xvalue). Which characteristics are required to be entered by the keypadwill depend upon the particular programming of the apparatus. There isnot one particular combination of parameters which are essential to theinvention.

Additionally, the controller may be programmed with a number of defaultvalues including L_(c), H_(min), pallet size. The controller may usethese default values or there may be a manual override for valuesentered from the keypad. From the default values and/or the operatorentered values, the parameters of the binding pattern can be determinedby the controller.

From the data corresponding to the distances L_(p), L_(c) and H_(b), thecontroller 108 is able to determine the distance H_(c) through which thetape dispensing apparatus must travel for the tape to be inclined atpitch H_(b) across each side of the load. In the exemplary arrangementshown in FIG. 12, the load 18 and pallet 23 have four sides, and apredetermined pattern of tape 80 is applied to the load 18 by drivingthe turntable 4 through a series of 90° rotations, and by driving thecarriage assembly 12 up and down the mast 8 to predetermined positionsprior to the completion of each of those 90° rotations.

To explain a typical binding sequence, FIGS. 21 and 22 show the entirebinding sequence for a four-sided load 500 consisting of two layers 501and 502 stacked on a pallet 503. The letters A, B, C and D refer to thesides of the load 500. The exemplary load positions referenced 401 to432 in these Figures demonstrate the manner in which a multiple-Xpattern is applied to the load 500 by the tape binding apparatus 2.Initially, the operator from the keypad selects an X value of 2 to beapplied to the load 500 and enters the top drop 504 and minimum tapeheight 505.

Once tape is applied to the load 500 in position S, the turntable isrotated through 90° and the carriage assembly 12 driven so that the tapedispensing means 20 dispenses tape at the minimum tape height 505. Sincethe X value is 2, the height at which the helixes of tape will cross atthe edges of the load 500 will be midway between the top drop andminimum tape heights 504 and 505. In position 402, the carriage assemblyis driven so that the tape is dispensed from a position higher than thisintermediary X point 506 in order to ensure that tape crosses the cornerat the intermediate height 506. In position 403, the load 500 is againrotated and the carriage is driven to a height in order that tape can beapplied on face C from the intermediary X point height 506 to the topdrop height 504. The carriage will thus overshoot the top drop height504 to apply tape at top drop height 504.

At position 404, the carriage assembly is driven back down to the topdrop height 504 in order to dispense tape horizontally and apply aportion of the top band at the top drop height 504. In position 405, thecarriage assembly 12 is driven down the mast 8 to a position below theintermediate X point height 506 in order that tape can be applied onface A from the top drop height 504 to the intermediate X point height506.

In position 406, the turntable 4 once again rotates and tape is appliedbetween the intermediate X point 506 height and the lower portion of theload 500. In this case, the carriage assembly 12 is unable to be drivenso that the tape dispensing means is below the height of the pallet 503and the tape is only able to be applied at the minimum tape height 505upon a further rotation of the pallet as shown in position 407. Inposition 408, the load is rotated a further 90 on the turntable 4 and aportion of a band is applied at the minimum height 505. Positions 409 to432 illustrate the manner in which the tape is applied to complete thepattern to the load 500. In this pattern, it will be appreciated thattape is applied to the load 18 in a series of spaced upward and downwardhelixes positioned so that the helixes cross at predetermined locations.

It will be appreciated that having entered data indicative of the palletand load and optionally certain characteristics of the pattern to beapplied to the load and having been programmed with the known physicaldimensions of the carriage assembly, tape dispenser and displacementbetween the mast 8 and the centre of the turntable, the controller 108is able to operate the motors 32 and 44 in order to apply the tape in adesired pattern to contain the load 500.

FIGS. 13 and 14 illustrate a series of steps that the computer programstored in the PROM 112 causes the controller 108 to undertake in orderto apply a pattern to the load 18 such as the pattern described above inconnection with FIGS. 22 and 23. At step 200, a program corresponding toa desired pattern is loaded into the PROM 112. At step 202, datacorresponding to the load and pallet dimensions, and data defining thecharacteristics of the particular pattern to be applied to the load, areentered via the keypad 114 or default values are loaded from memory. Atstep 204, the program is then activated by the operator. At step 206,the controller 108 fetches the first instruction of the computerprogram. This instruction causes the motor 32 to be activated to drivethe turntable sprocket 26 in a clockwise direction. At step 208, thecontroller counts a predetermined number of pulses from the sensor 60corresponding to a 90° rotation of the turntable. At step 210, once the90° rotation of the turntable has occurred, the controller fetchesinstructions for the second cycle of the program. In this step, thecontroller again energises the motor 44 to drive the carriage assembly112 to a desired position along the mast 8, and subsequently causes asecond 90° rotation of the turntable 4 to occur by energising the motor44. Once again, output signals from the sensor 60 and 64 are used toconfirm when the 90° rotation has occurred and when the carriageassembly 12 has been displaced to a desired position.

Typically, predefined patterns are applied to the load 18 by binding thetape 80 around two or more faces of the load 18 in a generally upwarddirection, and then applying the tape to two or more faces of the load18 in a generally downward direction. Horizontal bands may optionally beapplied between the upward and downward application of the tape.Accordingly, at step 212, the controller determines whether more than Xcycles have occurred, where X corresponds to the number of sides towhich the tape is to be applied in a generally upward direction.Accordingly, at step 112 the controller determines whether more than Xcycles have occurred. If not, the turntable 4 is again rotated, and thecarriage assembly 12 is driven in the upward or positive direction atstep 214, prior to the fetching of the instructions for the next cycle.

However, if more than X cycles have been performed, instructions for thenext cycle are fetched at step 216. In order that a horizontal band isapplied to an uppermost layer of the load 18, the carriage assembly 12is not driven, but the turntable 4 is caused to rotate through 90°, assensed in step 218. At step 220, instructions for the next cycle arefetched. Once again, in order to apply a horizontal band at theuppermost layer of the load 18, the turntable is driven through 90°, assensed in step 222.

At step 224, instructions are fetched for the following cycle. In thisexample, these instructions correspond to a first cycle in theapplication of tape 80 to the load 18 in a generally downward sense. Thepredetermined pattern to be applied to the load 18 includes X suchcycles, and accordingly at step 226, a determination is made as towhether these X cycles have been performed. If not, the carriageassembly 12 is driven down the mast 8 by causing the motor 44 to bedriven in the opposite direction. In addition, the motor 33 is caused todrive the turntable 4 through another 90° rotation. Once it has beendetected at step 228 that the carriage assembly 12 has been driven downto a desired position and that the turntable 4 has been rotated through90°, instructions for a subsequent cycle are fetched. The tape iscontinued to be applied to the load 18 in this manner until a desiredpredefined pattern has been applied to the load.

Various patterns may be applied to the load 18 as shown in the FIGS. 15to 20. Different predefined patterns may be applied to the entirety ofthe load 18. Alternatively different predefined patterns may be appliedto separate portions of the load 18. The patterns may simply varybecause of the different load parameters entered into the keypad by theoperator. Alternatively, different pattern options may be selected bythe operator.

Another example of the multiple X pattern shown in FIGS. 21 and 22, isillustrated in FIG. 15. In this embodiment, the helixes cross at thecorners of the load at the mid height of the layers. The load 300includes 4 layers 301 to 304. Each of the corners of each layer 301 to304 is contained by an “X” formed from the crossing of two portions oftape. Accordingly, each layer is fully contained in this predefinedpattern. The X value of this pattern is thus 4. This pattern is anexemplary helical pattern, the characteristics of which are determinedby the load parameters entered by the operator through the keypad.

An alternate pattern is shown in FIG. 16. This pattern is referred to bythe applicant as “banding”, and enables a series of horizontal bands tobe applied around the load 300. The required band heights may be chosenby the operator. In this instance, bands 306 and 307 are applied aroundthe uppermost layer and the second lowermost layer of the load. Thecontroller 108 causes the carriage assembly 12 to be driven between thetwo positions required to apply the two bands 306 and 307, so that anincline of tape 308 is applied between the bands as the tape fleets upor down between banding levels.

FIG. 17 illustrates another variation to banding, known as“overbanding”. This is an option which may be selected by the operatorthrough the keypad. The pattern of FIG. 17 is applied as per the helicalpattern of FIG. 15. At the conclusion of the helical pattern, theoverbands are applied over the helical pattern. In FIG. 17, twooverbands 500 and 501 are shown. The overband 500 is applied to thelayer 304. The overband 501 is applied to the layer 303. It is possiblefor the operator to select the height of the overbands. The overband 500is applied initially by an inclined tape path from the conclusion of thehelical pattern at H_(min) up to the desired height. The overband 500 isthen applied with the carriage maintained at this height for at least awhole revolution. The second overband 501 is then applied by incliningthe tape up ¼ revolution to the required height and making the secondoverband 501. For the sake of clarity, the inclined tape paths for eachquarter revolution to reach the desired heights of the overbands 500,501 are not shown in FIG. 17.

The benefit of overbanding is that the portions of the tape madeaccording to the default pattern can be cut above the second overband501. The presence of the overband 501 will mean that the remaining tapewound according to the helical pattern will not unravel. With the tapecut above the second overband 501, the top two layers 301, 302 can beremoved. The pallet can then be transported to another location where itis desired to remove the layer 303 from the pallet. To achieve this, theoverband 501 may be cut and the tape cut down to above the firstoverband 500, thus freeing the layer 303 from the tape binding. The load300 may then be transported to yet another location where all the tapemay be cut to remove the lowermost layer 304.

As previously mentioned, an operator can select the X value, namely thenumber of sides traversed by inclined sections of tape from the minimumtape height to top drop. Unlike the bound load illustrated in FIG. 15,it is sometimes not necessary to place an “X layer” on each layer ofcontainers in a load in order to achieve containment of the load. Lightloads or shallow containers may require an “X” only every second orthird layer of containers. This is because such a pattern will result insteeper angles on the inclined section of tape. This results in agreater downward force component tending to bind the load to the pallet.

As shown in FIG. 18, a single band of tape, or a top strap, may beapplied to the load above the main pallet load to contain items placedon the load as a partial layer. For example, in the last few cartons ofa production run there may be insufficient quantities of cartons to makeup a full layer. Typically, the top strap is constructed at the start ofa pattern sequence. In this way, the load integrity is retained if thepartial layer is removed. The top strap option may be selected via thekeypad and the top strap height may be input manually via the keypad.

Should the operator wish to apply the banding pattern shown in FIG. 19to the load 300, the operator selects the banding option through thekeypad, and enters the total number bands to be applied to the load 300as well as the height of each band, and the start and finish height ofthe tape attachment points. On initialisation, the carriage assemblytravels to the start height and stops in order that the operator canmanually apply the tape to the load 300. Once applied, the turntablerotates to apply the first band at the top height to the load 300, andthen moves to the next band height to apply the second band, the tapefleeting between the first band height and the second band height aroundthe exterior surface of the load 300. The banding process continuesuntil the lower most band is applied to the load.

Another pattern that may be applied to the load 300 is known by theapplicant as “looping”. As seen in FIG. 20, in this pattern, tape isapplied over the top corners of a load in order to cover or secure eachedge of the load. Looping is found to be particularly useful where anumber of flat sheets or containers, for example, are stacked and it isdifficult to effectively provide multiple patterns to the side faces ofthe stack flattened boxes. Typically, the looping pattern is applied bythe tape in a downward manner and in a sidewards manner to secure theflattened boxes or like stacked items.

FIGS. 28 and 29 more accurately reflect the steps required to achieve alooping pattern. In the example of FIGS. 28 and 29, the X number isthree. It can be seen that the process commences as would be expectedwith a three X pattern up to step 706. However, at step 707, instead oftraversing downwardly, the carriage moves to a distance D_(o) above thetop of the load which is referred to as “overshoot”. This causes thetape to pass over the top of the load, instead of traversing the corneraround the two sides C, D. The operator has the opportunity to input avalue for overshoot through the keypad. The controller will ask for anovershoot value once the looping option is selected.

FIGS. 26 and 27 show the effect of changing the value of overshoot. InFIG. 26, a smaller overshoot D₁ is entered by the operator. The choiceof overshoot effects the positions 801 and 802 where the tape crossesbetween the sides of the load and the top of the load. As can be seen inFIG. 26 c, a smaller overshoot results in a relatively shallow loop.

In FIG. 27, a larger overshoot D₂ has been selected which will result incrossing points 803 and 804 producing a deeper loop across the corner asshown in FIG. 27 c.

It will be appreciated that the carriage needs to travel a considerabledistance in order that the tape be applied from the top of the load tothe crossing point 805 as shown in FIG. 26 b. Thus, if the carriagespeed is maintained constant for the duration of the binding pattern,the turntable speed will be relatively slow for this portion of thepattern. The control of the relative turntable and carriage speeds isexplained further in conjunction with FIG. 23.

FIG. 23 shows in schematic form a modified version of the tape bindingapparatus 2′. The tape binding apparatus 2′ has a number of features incommon with the tape binding apparatus shown in FIGS. 1 to 12.Accordingly, like numerals reflect like parts. However, where the partshave been adapted to conform to the new embodiment, a prime symbol (′)will be used to indicate a modification to that part.

The mechanical aspects of the tape binding apparatus 2′ may besubstantially similar to that of the tape binding apparatus 2 in that itincludes a turntable 4 with a toothed wheel 62. The sensor 60 determinesthe passing of the toothed wheel and pulses are counted by controller108′. A mast 8 with a moveable carriage 12 driven via a drive chain 42is provided. The carriage 12 carries a roll of tape 17.

Additionally, the carriage includes a detector 900 in the form of aphotoeye which projects a beam of infrared light in a substantiallyhorizontal direction towards the load. The photoeye 900 is able todetect light which is reflected back from the load and can thusaccordingly detect the presence of the load. The photoeye 900 isattached to the carriage 12 and thus moves with the carriage 12. Thephotoeye 900 will thus detect when the carriage 12 has moved beyond thetop of the load. Through the use of photoeye, the top of the load willbe detected automatically and accordingly, it will not be necessary forthe operator to measure the height of the load and key this in throughthe keypad.

The carriage motor 44′ has associated therewith a toothed wheel 66. Thesensor 64 is mounted adjacent the toothed wheel in order to sensor thenumber of teeth passing on the toothed wheel 66. pulses are fed to thecontroller 108′ where they are counted to determine the displacement ofthe carriage 12 along the mast 8. A sensor 902 is also mounted adjacentthe toothed wheel 66 in order to determine the direction of rotation ofthe toothed wheel 66. Accordingly, the sensor 902 is able to verifywhether the carriage is travelling up or down.

A lower limit sensor 906 is provided to detect when the carriage is atthe lower extremity of the mast. The carriage cannot drive below thislower extremity. The bottom limit sensor is used to zero the count fromthe sensor 64 which provides an indication of the carriage position onthe mast.

A mast top limit sensor 904 is provided to indicate that the carriage isat the upper extremity of the mast 8. The carriage cannot drive abovethe upper extremity.

The keypad allows the operator to key in various load parameters as wellas selected pattern parameters. In this embodiment, these include theminimum tape height H_(min), top drop T_(d), pallet dimensions of lengthL_(p) and breadth. Additionally, the operator may input an incremental Xnumber. This is the variation to the default X number which would beautomatically determined by the machine given the pattern selection andload parameters. For example, the operator may key in plus 1 which wouldresult in an additional X applied to the load. Plus 2 will result in twoadditional Xs. Minus 1 will result in a lesser number of Xs etc. Theoperator may alternatively select the default setting.

The operator may also key in the maximum speed of the turntable. Theturntable will not rotate above this speed. The turntable speed isautomatically calculated (as will be explained). Thus, if the calculatedvalue exceeds the maximum speed entered by the operator, the turntablewill run at maximum speed.

The above parameters which are entered by the operator tend to be basedon the type of product being bound not the actual load being bound. Forexample, in order to bind a load of bottles set on trays in layers, theminimum tape height and pallet dimensions may be determined by the typeof pallet that the bottles are typically loaded onto. Top drop will beinfluenced by the shape of the bottles and likewise X number. Themaximum speed will reflect the maximum speed that the turntable can berotated without the bottles falling off the load. Thus, once theseparameters are set by the user, they need not be changed from load toload.

The operator may also key in other parameters e.g. selection of loopingor banding etc. Importantly, the actual load height does not need to bekeyed in as this is automatically determined by the photoeye 900.

Thus it can be seen from FIG. 23 that the controller 108′ receivesinputs from the turntable sensor 60, the top limit sensor 904 and thebottom limit sensor 906, the photoeye 900, the carriage position sensors64 and 902 and the keypad 67. The controller 108′ may conductcalculations based on the inputs in order to bind the load with tape.Based on these calculations, the controller 108′ will generate outputsto the turntable speed drive 106 to drive the turntable motor 32 and tothe variable speed drive 104′ of the carriage to drive the carriagemotor 44′. The infinitely variable speed drive 106 receives an analogsignal from the controller 108′ to drive the variable speed motor 32.

The variable speed drive 104′ for the carriage drives the carriage motor44′ at either of two speeds i.e. either fast or slow. Furthermore, thecarriage motor 44′ may be driven in either direction resulting in thecarriage travelling up or down. There are three outputs from thecontroller 108′ to the variable speed drive 104′. These include up, downand fast. If there is a fast output from the controller then thecarriage will be driven at the fast speed. Otherwise, the carriage willdrive at the slow speed. These fast and slow speeds may be inherent inthe variable speed drive 104′.

The diagrams of FIGS. 24 and 25 show the sequence of applying tape to aload using the apparatus of FIG. 23. In step 601, the operator attachesthe tape to the load and presses the start key on the keypad. Thecarriage 12 then drives to the lower extremity of the mast where itstops. The mast proximity counter associated with sensor 64 is thenzeroed. The carriage then drives up to the minimum tape height as inputby the operator and stops.

In step 602, the turntable begins to rotate. After a ¼ of a turntablerevolution, as shown in step 603 the carriage begins to ascend at a slowspeed. However, as the carriage begins the binding sequence at thebottom of the mast 6, the photoeye 900 has not detected the height ofthe load and thus the appropriate calculations to determine pitch cannotbe done by the controller 108′. Accordingly, the tape is applied at adefault pitch. This default pitch will depend upon the incremental Xnumber. If the incremental X number is the default factory setting, thenthe default pitch P _(d) will be 330 millimeters. The following sets outthe default pitches P_(d), based on the operators selected incremental Xnumber:

-   X number plus 2, tape pitch: 250 millimeters-   X number plus 1, tape pitch: 280 millimeters-   X number F, tape pitch: 330 millimeters-   X number minus 1, tape pitch: 400 millimeters-   X number minus 2, tape pitch: 500 millimeters

The above default pitches are merely examples and different values couldbe provided where the turntable and/or carriage speeds are altered.

The carriage will travel upward to apply the tape at the default pitchuntil the photoeye 900 detects the top of the load. The photoeye 900 isa sufficient distance above the tape dispenser apparatus in order thatthe photoeye will detect the top of the load before the tape reaches thetop drop. When the photoeye detects the top of the load in step 605, thecontroller 108′ reads the mast pulse count, thus measuring the height ofthe load. By deducting the top drop and the minimum tape height, thecontroller can determine the array height. Once the array height isknown, the corrected pitch H_(b) can be determined. The corrected pitchH_(b) is determined by dividing the array height by the default pitch.The resultant number is then rounded to the closest whole number toobtain the X number. The corrected pitch H_(b) is then derived bydividing the array height by the X number. This can be represented asA/P_(d)=Z

Round Z to nearest whole number (X)H_(b)=A/X

Thus, as shown in steps 607, 608 and 609, the tape will be applied toeach side of the load at a corrected pitch H_(b).

However, it will be appreciated that in the step 603, 604 and 605, theapplication of tape at the default pitch will hardly ever coincide withthe top drop T_(d) at the top of the upward helix. Accordingly, someadjustment will be required for the tape to reach the top drop position.When the photoeye detects the top of the load, as described above, thecontroller 108′ will be able to determine the array height, and fromthis the required number of tape crossings at the default pitch for thetape to reach this tape height. Thus the controller can determine howfar the load should rotate until the required side of the load ispresented for tape to be applied. At the time of detecting the top ofthe load, the controller 108′ reads the turntable pulse count whichdetermines the orientation of the turntable 4 from information suppliedby sensor 60. The pulse count will enable the controller to determinethe actual orientation of the turntable. Thus, the controller willcontrol the turntable to continue to rotate until the required face ofthe load is presented which coincides with the top of the tape ascent.

If the turntable is already presenting this face, binding as per thecorrected pitch will start immediately. If the required face is yet tobe presented the turntable will continue to rotate. The example shown insequence step 606 shows this situation where a small increment in tapeheight is required in order to reach top drop. This tape is applied atan adjusted pitch P_(a). If however the required face is already beingpresented when the top of the load is detected, then an adjustment maybe required in step 605 if the remaining distance to reach top drop isless than the default pitch. Accordingly, in step 605 the pitch would beless than the default pitch shown. In this eventuality, in step 606, thetape would be applied level.

From step 607 onwards, the apparatus continues to bind the loadaccording to the corrected pitch resulting in a corrected patternapplied to the load. It will be appreciated from FIGS. 24 and 25 thatthe tape goes up and down four times in order to bind the load. One ofthese ascents will be according to a default pattern and a defaultpitch, whereas the remaining ascents and all the descents will beaccording to the corrected pattern at the corrected pitch. Thus, ⅛^(th)of the binding pattern will be at the default pitch whereas ⅞^(th) ofthe binding patterning will be at the corrected pitch.

From step 607 onwards, the carriage travels at the fast speed. It is tobe understood that the carriage only has two speed options being fastand slow and both the fast speed and the slow speed are substantiallyconstant apart from the necessary deceleration and acceleration requiredwhen transitioning from up to down.

Given that the carriage travels at a constant speed, it is thusnecessary for the turntable to travel at variable speeds in order thatthe pattern may be applied to the load in the desired manner. At thedefault pitch, the required positions for the tape dispenser at eachquarter revolution can be determined. Likewise, once the corrected pitchhas been calculated, the required positions for the carriage at eachquarter revolution of the turntable will be known. The controller 108′thus calculates the required speed for the turntable so that it travelsexactly ¼ revolution in the time taken for the carriage to travel fromone destination to the next. The turntable speed calculation means thatthe carriage will not actually stop at the required position. Rather, aconstant speed will be maintained for each ascent and descent (subjectto acceleration and deceleration at the extremes). As the distancebetween carriage destinations will vary, depending upon whether itapplies sequential inclined runs of tape or horizontal bands of tape,the turntable's speed will continually adjust itself accordingly. Forexample, when horizontal runs of tape are applied in banding or at thebottom of the load, the distance to the next carriage destination willthus be small (or zero in the case of two sequential horizontal runs oftape). The calculated turntable speed will thus be high. In such a case,the turntable will rotate at the maximum speed which was input by theoperator. This method of speed control results in the absolute minimumcycle time because it enables the carriage to run at the fastestpossible safe speed i.e. a speed which is not dangerous and also allowsappropriate stopping at the upper and lower limits as required. Thus,the turntable adjusts to suit this maximum possible speed. This is agreat saving in the binding time for a load over existing methodsbecause in existing methods the speed of the carriage (which needs totravel up and down at least four times) is the limiting factor.

In step 637 shown in FIG. 25, the turntable slows to predetermined creepspeed and then stops at the same rotational position from which itstarted.

FIG. 30 illustrates a variation which may be applied to any of thebinding sequences illustrated in FIGS. 21, 22, 24, 25, 28 and 29.Instead of the operator needing to bend over to apply the tape to thebase of the load, there is a programmed “home position” 920 for thecarriage which is at an appropriate height for the operator to grab theend of the tape and apply it to the load at that height. This saves theoperator from having to bend down.

It will be understood that the invention disclosed and defined in thisspecification extends to all alternative combinations of two or more ofthe individual features mentioned or evident from the text or drawings.All of these different combinations constitute various alternativeaspects of the invention.

1. An apparatus for binding a three-dimensional load with tape, the apparatus comprising: a turntable for supporting and rotating the three-dimensional load; a tape dispenser for dispensing tape, the dispenser being moveable relative to the turntable and the load; a logistical controller arranged to control rotation of the load and movement of the tape dispenser; and a detector to detect the top of the load, the detector being moveable with the tape dispenser, wherein the controller is arranged to operate the apparatus to dispense the tape according to a predetermined default pattern until the detector determines the top of the load, whereafter, the controller is responsive to a signal from the detector corresponding to the detected top of load to operate the apparatus according to a corrected pattern based upon the detected top of load.
 2. The apparatus as defined in claim 1 wherein the tape dispenser is provided on a moveable carriage driven up and down a mast, and the detector is mounted on the carriage.
 3. The apparatus as defined in claim 2 wherein the detector is spaced above the tape dispenser to provide advance warning to the controller in an upward path of the tape dispenser that the tape is approaching the top of the load.
 4. The apparatus as defined in claim 1 wherein the corrected pattern applied to the load is a helical pattern comprising a plurality of upward and downward helixes which are spaced from each other with at least some of the upward helixes crossing at least some of the downward helixes, the upward and downward helixes extending between upper and lower limits and wherein the default pattern comprises an upward helix and the controller operates the apparatus to dispense the tape in the upward helix of the default pattern according to a default pitch.
 5. The apparatus as defined in claim 4 wherein the tape is applied at a default pitch until the detector detects the top of the load, whereafter the controller calculates a corrected pitch and operates the apparatus to apply the remaining upward and downward helixes at the corrected pitch.
 6. The apparatus as defined in claim 5 wherein the corrected pitch is calculated so that the tape will be applied to a whole number of sides of the load as it traverses between the upper and lower limit and vice versa.
 7. The apparatus as defined in claim 1 wherein the controller controls the apparatus to commence at an intermediate height of the load.
 8. The apparatus as defined in claim 4 wherein the controller is arranged to receive a number of user inputs through the use of a keypad or other data entry means including values corresponding to the upper and lower limits of the pattern array, the pattern array being the vertical extent of the applied default and corrected helical patterns.
 9. The apparatus as defined in claim 8 wherein the controller is arranged to calculate the array height from an input from the detector and the values corresponding to the upper and lower limits of the pattern array and wherein the controller determines the corrected pattern based on the array height.
 10. The apparatus as defined in claim 4 wherein the controller determines an adjustment which is required in the default pattern so that the tape reaches the upper limit coinciding with the end of an inclined pass of tape across a side of the load.
 11. A method of binding a three-dimensional load with tape, the method comprising: a) binding the load with tape dispensed from a movable tape dispenser according to a default pattern; b) detecting the top of the load by a detector moveable with the tape dispenser during step a); and c) binding the load with a corrected pattern based on the detected top of load.
 12. An apparatus for binding a three dimensional load with tape, the apparatus comprising: a turntable to rotate the load; a carriage to carry a tape dispenser for movement along an upward path and a downward path adjacent the load; a controller to control the movement of the turntable and the carriage to bind the load according to a desired pattern, wherein the controller comprises a computer program which calculates the required turntable speed for a substantially constant predetermined speed of the carriage over a substantial portion of the upward path or a substantial portion of the downward path such that the relative position of the turntable and the carriage is such that the load is bound according to the desired pattern.
 13. The apparatus as defined in claim 12 wherein the carriage speed is constant over an intermediate portion of both of the upward and the downward paths to allow for acceleration and deceleration at the extremes of the paths.
 14. The apparatus as defined in claim 13 wherein the apparatus is operable to determine predefined parameters of the load during the binding operation and the carriage has two possible constant speeds being a fast speed and a slow speed and wherein the controller is arranged to operate the apparatus to apply tape at the slow speed to apply a default pattern which is pre-programmed into the controller and the controller is arranged to operate the apparatus to apply tape at the fast speed according to a pattern which is determined by the controller once the predefined parameters of the load are determined.
 15. The apparatus as defined in claim 12 wherein the apparatus is adapted to bind a three dimensional load which is square or rectangular and the desired pattern for the tape is broken down into segments of quarter turns of the turntable by the controller to determine, for each quarter turn: the required position of the carriage to apply tape according to the desired pattern; when the carriage will arrive at the required position; and the speed of the turntable required to rotate the load through said quarter turn.
 16. An apparatus for binding a load with tape, the apparatus comprising: a turntable for supporting and rotating the three-dimensional load; a tape dispenser for dispensing tape, the dispenser being moveable relative to the turntable and the load; and a logistical controller arranged to control rotation of the load and movement of the tape dispenser; wherein the controller is arranged to operate the apparatus to dispense the tape according to a desired pattern comprising a plurality of helical paths, each path including at least one upward helix, a loop over the top of the load and a downward helix giving rise to a pattern whereby the upward and downward helixes are transversely spaced from each other and each upward helix crosses with at least one downward helix.
 17. The apparatus as defined in claim 16 wherein the apparatus includes a data entry means for the operator to select the desired pattern from a variety of pattern options.
 18. The apparatus as defined in claim 17 wherein the data entry means is also adapted to receive operator entry of one or more parameters of the looping.
 19. An apparatus for binding a three-dimensional load with tape, the apparatus comprising a turntable for supporting and rotating the three-dimensional load; a tape dispenser for dispensing tape, the dispenser being moveable relative to the turntable and the load; and a logistical controller arranged to control rotation of the load and movement of the tape dispenser, wherein the logistical controller controls the operation of the apparatus to bind the load with tape according to a desired pattern; and means for inputting into the logistical controller, one or more values corresponding to one or more selected heights, wherein the logistical controller controls the operation of the apparatus to apply substantially horizontal over-bands over the desired pattern at the one or more selected heights.
 20. The apparatus as defined in claim 19 wherein the desired pattern applied to the load is a helical pattern comprising a plurality of upward and downward helixes which are spaced from each other with at least some of the upward helixes crossing at least some of the downward helixes
 21. An apparatus for binding a three-dimensional load with tape, the apparatus comprising: a turntable for supporting and rotating the three-dimensional load; a tape dispenser for dispensing tape, the dispenser being moveable relative to the turntable and the load; and a logistical controller arranged to control rotation of the load and movement of the tape dispenser to dispense tape onto the load in a desired pattern, wherein the controller is programmed to position the tape dispenser at a home position which is at a convenient height for the user to position tape on the load and wherein the controller is arranged to control movement of the tape dispenser to a start position to commence application of tape to the load in the desired pattern. 